CoatingsPro Magazine

JAN 2009

CoatingsPro offers an in-depth look at coatings based on case studies, successful business operation, new products, industry news, and the safe and profitable use of coatings and equipment.

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NEVER AGAIN FARMER'S FLOOR IS A NIGHTMARE HARVEST 10,000 square foot concrete floor in his utility building began to crack and spall, he knew there was more to the f loor's premature failure than simple "bad luck." But the failure's fix yielded a crop of lessons that all involved won't soon forget. Y A successful Midwestern farmer — with approximately 5,000 arable acres — had built what he modestly describes as a "tool shed" to store and repair his large ride-on John Deere farming equipment, tools, and other supplies. However, at 10,000 square feet, the BY FLOYD DIMMICK SR. AND JENNIFER KRAMER PHOTOS COURTESY OF BODYTEK COATINGS GROUP AND CROWN POLYMERS ou've heard of the "Farmer in the Del l ," right? Wel l , this farmer was in "f loor- ing hell." When the year-old building is something more than a simple "shed." Two sides of the build- ing open in a manner akin to a garage door to allow the large farming equip- ment to pass through. The openings are designed similar to overhead aircraft hangar doors, without center column supports. The opening swing door on the narrow end is 60 feet wide and the side door is 70 feet wide. The rear third of the building is dedicated to the comfort of the farmer's crew and features shower facilities and a kitchen area. Also for the comfort of all, the building features radiant heating within the concrete floor. Less than a year after the struc- ture was built, heavy spalling and large cracks began to appear across the floor's "The huge floor only had one expansion joint running across it approximately at its center. The floor had no control joints," Adney describes. "It was interesting." 80 CoatingsPro J January 2009 ABOVE "Our first look showed a beautiful building with lots of special comfort features, and then we saw the floor," says BodyTek's Mark Elijah. In an effort to smooth the floor, a milling machine had been used as a scarifica- tion tool. Instead of creating a smooth surface, it had the opposite effect, leaving deep grooves up to 3/8" in the concrete floor. Elijah continues, "Approximately 800 sq. ft. looked like raised corn rows." expanse. An attempt by the farmer's employees to correct the problem themselves only created a larger problem. So, the farmer contacted Bob and Jeff Adney of BodyTek Coatings Group. Problems Keep Cropping Up "When we got there, it was easy to see at least one of the causes of the problems," recounts Jeff Adney. "The concrete floor was unsealed." Given the building's intended use — the storage and repair of heavy equipment and farming supplies, it was a puzzle why the floor was not properly sealed or overlaid. But as no explanation was forthcoming (or ever given) the BodyTek crew simply had to move forward with their own insights and

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